Catalyst compositions

The present invention relates to catalyst compositions and to processes for preparing interpolymers of olefins and carbon monoxide by polymerising a mixture of one or more olefins and carbon monoxide in the presence of such catalyst compositions. In particular, the present invention relates to novel compounds and their use in catalysts for such processes.

The preparation of linear alternating interpolymers of olefins and carbon monoxide having the formula: ##STR1## where the R groups are independently hydrogen or hydrocarbyl groups, n is at least 1 and m is a large integer, is known from U.S. Pat. No. 3,694,412. Such linear alternating interpolymers, which hereafter will be called polyketones, are prepared according to U.S. Pat. No. 3,694,412 by polymerising a mixture of one or more olefins and carbon monoxide in the presence of an aryl phosphine complex of a palladium halide and an inert solvent. However, the processes described in U.S. Pat. No. 3,694,412 are slow even at elevated temperature and pressure.

An improved version of the process described in U.S. Pat. No. 3,694,412 is described in European patent applications 181014 and 121965. It was subsequently found that the rate of the polymerisation process could be increased considerably by using a palladium catalyst with inter alia a bidentate phosphine and the anion of a carboxylic acid having a pKa of lower than 2 (as measured in aqueous solution). Examples of anions which can be used include trichloroacetate, dichloroacetate, tetrafluoroborate, hexafluorophosphate and p-toluene sulphonate, such anions being respectively the conjugate anions of trichloroacetic acid, dichloroacetic acid, tetrafluoroboric acid, hexafluorophosphoric acid and p-toluenesulphonic acid.

More recently EP 222454 suggests that any acid having a pKa of less than 5 (determined in aqueous solution at 18° C.) can be used.

It has now been found that instead of using the bidentate diphosphine as described in EP 121965, catalyst systems, in particular palladium catalyst systems, for the production of polyketones based upon novel phosphine ligands can be employed.

According to the present invention there is provided a catalyst composition prepared by reacting together:

(a) a source of a Group VIII metal,

(b) a bidentate phosphine ligand having at least two phosphorus atoms joined by a bridging group of the formula --NR 2 (CX)NR 2 where X═O, S or Se, each R 2 is the same or different and is a hydrogen or hydrocarbyl group, and

(c) a promoter.

The present invention further provides a process for preparing polyketones by polymerising a mixture of carbon monoxide and one or more olefins in the presence of a catalyst composition as defined hereinabove.

The term polyketone is used herein to mean an interpolymer of one or more olefins with carbon monoxide. The idealised structure of such a material would comprise a one, two or three dimensional network of strictly alternating olefin and carbon monoxide units. Although polyketones prepared according to the present invention correspond to this idealised structure, it is envisaged that materials corresponding to this structure in the main but containing small regimes (i.e. up to 10 wt %) of the corresponding polyolefin also fall within the definition.

The catalyst composition described above is itself prepared by reacting together (a) a source of a Group VIII metal, (b) a compound having the formula defined above, and (c) a promoter.

As regards component (a), this is a source of Group VIII metal; the Group VIII metals are iron, cobalt, nickel, ruthenium, rhodium, palladium, osmium, iridium and platinum. The second-row Group VIII metals (i.e. ruthenium, rhodium, palladium) are preferred; particularly preferred is palladium.

Component (b) is a bidentate phosphine ligand having at least two phosphorus atoms joined by a bridging group of the formula --NR 2 (CX)NR 2 where X═O, S or Se, each R 2 is the same or different and is a hydrogen or hydrocarbyl group. In particular component (b) can be a compound of formula I: ##STR2## where R 1 is hydrocarbyl and R 2 is hydrogen or hydrocarbyl, each R 1 can be the same or different and each R 2 can be the same or different,

R 1 is a hydrocarbyl group for example an alkyl preferably a C 1 -C 6 alkyl group, alternatively R 1 can be an aryl group optionally substituted with a polar group for example phenyl or o methoxy phenyl. The hydrocarbyl group can be a substituted or unsubstituted hydrocarbyl group. R 2 on the other hand is hydrogen or a hydrocarbyl group for example a C 1 -C 6 alkyl group for example methyl or ethyl or an aryl group for example phenyl.

In a further aspect of the present invention there is provided a compound of the formula (Ph 2 P)N(Me)CO(Ph)N(PPh 2 ).

As regards component (c) which is a promoter, this can be a source of an anion which is either non-coordinating or weakly coordinating. Such anions are suitably the conjugate bases of strong acids having e.g. a pKa of less than 6 preferably less than 2 (e.g. HBF 4 , HPF 6 , HSbF 6 , paratoluene sulphonic acid). Alternatively, the promoter can be a boron hydrocarbyl compound for example a boron alkyl or boron aryl compound. In particular the Boron hydrocarbyl compound can be a Lewis acid of the formula BXYZ where at least one of X Y and Z is a monovalent hydrocarbyl group. Where any one of X Y or Z is a monovalent hydrocarbyl group, it is suitably an alkyl for example a C 1 -C 6 alkyl group, or an aryl group for example, a substituted or unsubstituted phenyl group for example C 6 H 5 or C 6 F 5 . Other suitable monovalent hydrocarbyl groups are p-Hal C 6 H 4 (where Hal=F,Cl,Br), m, m-C 6 H 3 (CF 3 ) 2 , CF 3 and C 2 F 5 . It is to be understood that two or three of the groups X, Y and Z can together form bi or trivalent groups respectively. At least one of X, Y and Z is a monovalent hydrocarbyl group; however it is preferred that at least two, preferably three, of X, Y and Z are each monovalent hydrocarbyl groups. Suitable examples of such Lewis acids are BMe 3 , BEt 3 , B(C 6 H 5 ) 3 , B mm-(CF 3 ) 2 C 6 H 3 ! 3 , B(mesityl) 3 , B(p-Hal C 6 H 4 ) 3 (where Hal=F, Cl, Br), B(m-CF 3 C 6 H 4 ) 3 and B(C 6 F 5 ) 3 , preferably B(p-Hal C 6 H 4 ) 3 and B(C 6 F 5 ) 3 . Where one or more of X, Y and Z is not a hydrocarbyl group, it is suitably a OH, OR or halide group preferably a halide group for example fluoride, chloride or bromide especially fluoride. Examples of compounds where one of X, Y, Z is a group other than a hydrocarbyl group are boronic acids of the formula RB(OH) 2 where R is a hydrocarbyl group e.g. PhB(OH) 2 , and hydrocarbyl 1,3,2-benzodioxaboroles.

Other suitable boron hydrocarbyl compounds for use in this invention are borate salts of the formula MBR 4 where M is an alkali metal e.g. Li, Na, and R is a hydrocarbyl group e.g. C 6 H 5 , C 6 F 5 and substituted analogues. For example a suitable compound could be LiB(C 6 F 5 ) 4 or NaB(C 6 H 5 ) 4 .

When a boron hydrocarbyl compound is used, for example a Lewis Acid BXYZ it is added to the reaction medium in an amount such that the Group VIII metal: Boron ratio is in the range 10:1 to 1:200 preferably 1:1 to 1:100 more preferably 1:5 to 1:70 e.g. 1:50.

Alternatively, the promoter(c) can be an aluminoxane.

Where the Group VIII metal is palladium, the source of palladium can include simple inorganic and organic salts, e.g. halides, nitrates, carboxylates and the like as well as organometallic and coordination complexes. In some cases, by suitable choice of coordination complex, it may be possible to add the palladium and the compound of formula I as a single entity.

For example the novel compounds of formula II

L.sub.2 Pd(P--P) (II)

where each L is independently a monodentate ligand or L 2 taken together is a bidentate ligand and P--P is a bidentate phosphine ligand having at least two phosphorus atoms joined by a bridging group of the formula --NR 2 (CO)NR 2 where each R 2 is the same or different and is a hydrogen or hydrocarbyl group. In particular a compound of the formula II, where R 1 and R 2 have the meanings assigned to them as hereinabove, can be used together with component (c), a promoter. L in formula II is typically a halide or carboxylate ligand for example CH 3 COO or CF 3 COO. In a further aspect of the present invention there are provided compounds of formula II as defined.

Where the promoter is a non-coordinating or weakly coordinating anion, this can also be incorporated into a discrete compound as a counter anion. For example, novel compounds of the formula III can be used

L.sub.2 Pd(P--P)!(A.sup.1).sub.2 (III)

where L and P--P have the meanings assigned to them as in formula II above and A 1 is a non-coordinating or weakly coordinating anion. L is preferably a 2-electron donor ligand e.g. H 2 O, ROH (where R is a hydrocarbyl group e.g. Me, Ph), R 2 CO (where each R is independently a hydrocarbyl group e.g. Me) RCN (where R is an alkyl or aryl group). L is typically benzonitrile or a acetonitrile. An example of a compound of formula III is (benzonitrile) 2 Pd(P--P)!(BF 4 ) 2 where P--P is (Ph 2 P)N(Me)CO(Ph)N(PPh 2 ).

In a further aspect of the present invention there are provided compounds of the formula III.

Alternatively, the anion can be used in the form of a salt or its conjugate acid together with the Group VIII metal and the compound of formula I whether the latter two are added as a single discrete compound or are added as two components.

Although any source of the Group VIII metal can be used, it may be necessary, when a metal complex having strongly coordinating ligands is employed, to ensure that such ligands are removed. An example of such a complex is palladium acetate where the acetate ligands bind to the palladium. In such cases the acetate ligands can be removed by adding component (c) above for example as the conjugate acid of a non-coordinating or weakly coordinating anion since such a conjugate acid will protonate the acetate ligands and cause their removal.

Another approach which is useful when metal halides e.g. palladium halides are employed (halide anions also bind strongly to the palladium) is to use a thallium or silver salt of a non-coordinating or weakly coordinating anion. In such cases a metathesis reaction occurs and the insoluble silver or thallium halide precipitates and can be removed by filtration.

Considering next the feedstocks for the polymerisation reaction, it is believed that any source of carbon monoxide can be used. Thus the carbon monoxide may contain nitrogen, inert gases and up to 10% hydrogen.

Any olefin can in theory be used although the best reaction rates are obtained when either ethylene or ethylene and at least one other olefin e.g. ethylene/propylene and the like, is used. The lower rates obtained in the absence of ethylene should not be construed as indicating that the process can be used only with an ethylene feedstock since other olefins such as propylene, 4,methylpentene-1, styrene, acrylates, vinyl acetates and the like all undergo reaction to some extent. A preferred polyketone is a terpolymer of ethylene, propylene and carbon monoxide; under these circumstances the olefin will be a mixture of ethylene and propylene.

The catalyst compositions can be used in either the gas-phase or the liquid-phase. It is to be understood that the term liquid phase also includes slurry-phase where the polyketone product is insoluble in the reaction solvent.

Where the polymerisation process is in the liquid phase it is suitably carried out in a solvent which is chemically inert under the conditions employed and one in which the catalyst is soluble. Examples of such solvents include alcohols, e.g. methanol, ethanol and propanol, ethers, glycols, glycol ethers and chlorinated solvents e.g. chloroform and dichloromethane. Preferred solvents are methanol, ethoxyethanol, chloroform or dichloromethane especially dichloromethane. Alternatively, an aliphatic, tertiary alcohol can be used, preferably tertiary butanol. This can be used as a solvent on its own or in combination with an aprotic solvent, e.g. ketones. A preferred solvent system is tertiary butanol/acetone mixture.

The polymerisation process is suitably carried out at a temperature in the range 20° to 150° C. preferably 50° to 120° C. and at elevated pressure (e.g. 1 to 100 bars). The overpressure of gas is suitably carbon monoxide or carbon monoxide and olefin, if the olefin is gaseous under the reaction conditions. It is possible to operate the polymerisation process either batchwise or continuously.

The invention will be illustrated with reference to the following Examples.